In this paper we discuss a deployed application at Ford Motor Company that utilizes AI technology for the analysis of potential ergonomic concerns at our assembly plants. The manufacture of motor vehicles is a complex and dynamic problem and the costs related to workplace injuries and lost productivity due to bad ergonomic design can be very significant. We have developed two separate ergonomic analysis systems that have been integrated into the process planning for manufacturing system at Ford known as the Global Study and Process Allocation System (GSPAS). GSPAS has become the global repository for standardized engineering processes and data for assembling all Ford vehicles, including parts, tools and standard labor time. One of the more significant benefits of GSPAS is the use of a controlled language, known as Standard Language, which is used throughout Ford to write the process assembly instructions. AI is already used within GSPAS for Standard Language validation and direct labor management. The work described here shows how we built upon our previous success with AI to expand the technology into the new domain of ergonomics analysis.

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